Failure Mode & Effect Analysis

(FMEA)
Presented By:
Gaurav Sharma
(11ME033)

Guide
Prof. S. C. Pathak
Department of Mechanical Engineering
 Objectives
_______________________________________________
• FMEA Terms
• What is FMEA ?
• Why FMEA ?
• Types of FMEA
• History
• FMEA Form
• Who uses FMEA
• Procedure
• RPN
• Implementation into design Process
• Severity
• Occurrence
• Detection
• Example, Limitation, Advantages
 Fmea terms
_________________________________________
 Failure
• The loss of a function under stated conditions.

 A Failure Mode is:

• The way in which the components, subassembly, product,
input, or process could fail to perform its intended function.

• Things that could go wrong.

• Example: A fully fractured axle.

 Effects analysis
• Studying the consequences of the various failure modes to
determine their severity to the customer.
 What is Fmea ?
__________________________________________
 Failure Mode and Effect Analysis (FMEA) is a step by step
approach for identifying all possible failures in a design, a
manufacturing or a product or service.

 FMEA is an inductive reasoning (forward logic).

 It is a core task in Reliability Engineering, Safety Engineering

and Quality Engineering.

 It is based on experience with similar product or process or based

on common Physics of failure logic.

 Sometimes FMEA is Extended to FMECA to indicates that

criticality analysis is performed too.
 Why fmea ???
_________________________________________
 Methodology that facilitates Process Improvement.

 Improve internal and external customer satisfaction.

 Focuses on prevention.

 Identifying and eliminates concerns early in the development of

process or design.

 FMEA may be a customer requirement (likely contractual)

 FMEA may be required be an applicable

Quality Management System Standard (possibly ISO)
 Types of FMEa
_________________________________________

 Design – focuses on component and subsystems.

 Process – focuses on Manufacturing and Assembly processes.

 System – focuses on global system functions.

 Service – focuses on service functions.

 Software – focuses on software functions.

 History of fmea
_________________________________________

 An offshoot of 1949 Military Procedure MIL-P-1629, entitled

“Procedures for Performing a Failure Mode, Effects and
Criticality Analysis”
 Used as a reliability evaluation technique to determine the effect
of system and equipment failures.
 Failures were classified according to their impact on mission
success and personnel/equipment safety.
 Formally developed and applied by NASA in the 1960’s to
improve and verify reliability of space program hardware.
 The procedures called out in MIL-STD-1629A are the most
widely accepted methods throughout the military and commercial
industry.
 The fmea form
_________________________________________
 Who uses FMEA ???
_________________________________________
 Engineers Worldwide in :
 Nuclear Power plant.
 Aerospace
 Chemical Process Industries
 Automotive Industries
 Healthcare
 Goal has been, and remains, to prevent accident accidents from
occurring
 Fmea: a team tool
_________________________________________
 A Team approach is necessary.

 Team leader should be familiar with FMEA.

 The following should be considered for team members:

I. Design Engineers
II. Process Engineers
III. Materials Suppliers
IV. Operators
V. Reliability
VI. Suppliers
VII.Customers
 Fmea Procedure
_________________________________________
1. Determine failure mode for each process input.
2. For each failure mode, determine effects – Select a severity level
for each effect.
3. Identify potential causes of each failure mode – Select an
occurrence level for each cause.
4. List current controls for each cause – Select a detection for each
cause.
5. Calculate the Risk Priority Number (RPN).
6. Develop recommended action , assign responsible person and
take actions.
7. Assign the predicted Severity, Occurrence and Detection levels
and compare RPNs
 Risk Priority number (rpn)
_________________________________________
 Severity × Occurrence × Detection = RPN
• 1000 is maximum and 75* is considered OK!!!
• Severity (S)
• Importance of the effects on customer requirements.
• 1 = Not sever, 10 = very sever
• Occurrence (O)
• Frequency with which a given cause occurs and creates
failure modes.
• 1 = NOT Likely, 10 = Very Likely
• Detection (D)
• The ability of the current control scheme to detect then
prevent a given causes.
• 1 = Easy to Detect, 10 = Not easy to Detect
 Risk Priority number (rpn)
_________________________________________
 Risk Priority number (rpn)
_________________________________________
 Rating Scales
_________________________________________
 There are a wide variety of scoring anchors.

 Two types of scales are 1-5 or 1-10.

 The 1-5 scale makes it easier for the teams to decide on scores.

 The 1-10 scale may allow for better precision in estimates and a
wide variation in scores.

 Zero(0) Ranking not allowed for RPN Rating Scales.

 Fmea timing
_________________________________________

 FMEA should be updated –

 At the conceptual stage.

 When changes are made to the design.

 When new regulation are instituted.

 When customer feedback indicates a problem.

 Implementation into Design process
_________________________________________
 Ranking of Occurrence of Effect
Probability of Failure Possible Failure rates Ranking
Very High : Persistent >/= 100 per thousand cores 10
failure
50 per thousand cores 9
High : Frequent failure 20 per thousand cores 8
Moderate : Occasional 10 per thousand cores 7
failure
5 per thousand cores 6
2 per thousand cores 5
Low : Relatively few 1 per thousand cores 4
failure
0.5 per thousand cores 3
Remote : Failure is 0.1 per thousand cores 2
unlikely
</= 0.01 per thousand cores 1*
 Fmea table for ball-point pen
_________________________________________
 Fmea for Boiler tube
_________________________________________
Year No. of Failure

2009 A = 24 (Assume)

2010 B = 22

2011 C = 26

2013 D = 23

2014 E =19

2015 _
 Risk Analysis of Boiler using Failure Mode & Effect Analysis

Potential Potential Potential causes Severit Occu Detec RPN Control Process
failure effect of y rrenc tion Detection
mode failures (S) e (D)
(O)

Boiler 1. Water 1. Corrosion X=9 Y = 7 Z = 5 315 Water leakage

Tube leakage (let) (let) (let)
2. 2. Scale
Thickness of tube
Cooling formation
wall
process 3. Extremely
stop combustion
3. Unit 4. Creep Thermal stress
had shut failure
down 5. Poor water
4. Water Circulation
level not Increased tube
maintai strain
ned
Alarms
 HFmea Example
_________________________________________
 Suppose A Person who was a patient in the SMS Hospital, Jaipur.
He/she died suddenly cause of Swine Flu in the presence of her
physician and member of him/her family. He/she was alert and
oriented at the time and him/her condition, while very serious, did
not seem to indicate reason for immediate concern. Him/her
unexpected death was devastating for her family and extremely
distressing for all those involved in her care.

 An ICU physician suspected the cause - the composition of

solution being used to treat him/her failure. This was quickly
confirmed and 30 bags of the solution made in the same batch
were removed from patient care areas, undoubtedly preventing
the deaths of other patients and investigation that how to solve
detected problem.
 Advantages
_________________________________________
 Enhance design and manufacturing efficiencies

 Minimize exposure to product failures

 Augment business records

 Improve “bottom line” results

 Add to customer satisfaction

 Reliability also Improve

 Limitation
_________________________________________

 Employee training requirements

 Initial impact on product and manufacturing schedules

 Financial impact required to upgrade design, manufacturing, and

process equipment and tools

 References
_________________________________________
 http://en.wikipedia.org/wiki/Failure_mode_and_effects_analysis
 http://www.stat.purdue.edu/~kuczek/stat513/IT%20381_Chap_7.pp
t
 http://www.ise.ncsu.edu/wysk/courses/ise497/IE497Failure%20Mo
des%20and%20Effects%20Analysis%20%28FMEA%29.ppt
 http://castle.eiu.edu/~pingliu/tec5133/resources/spring_2010/studen
t_files/Failure%20Mode%20and%20Effect%20Analysis.ppt
 http://www.coe.montana.edu/me/faculty/larson/MET456_457/Failu
re%20Modes%20and%20Effects%20Analysis%20%28FMEA%29.
ppt
 B U Sonawane, Dr. B Rajiv, P K Chattopadhyay (2010), “Critical
and Hazard Analysis of Various Components in a System using
Risk Priority Number and Analytic Hierarchy Process”, IE(I)
Journal-PR, Vol. 90, Page No. 18-23.
Thank
You!!!